3-D diamond printing using a pre-ceramic polymer with a nanoparticle filler

Patent metadata

Field	Value
Publication number	US-9943979-B2
Application number	US-201615090289-A
Country	US
Kind code	B2
Filing date	Apr 4, 2016
Priority date	Mar 7, 2014
Publication date	Apr 17, 2018
Grant date	Apr 17, 2018

Abstract

According to some embodiments, a method includes depositing alternating layers of a ceramic powder and a pre-ceramic polymer dissolved in a solvent. Each layer of the pre-ceramic polymer is deposited in a shape corresponding to a cross section of an object. The alternating layers of the ceramic powder and the pre-ceramic polymer are deposited until the layers of the pre-ceramic polymer form the shape of the object. The method includes heating the deposited ceramic powder and pre-ceramic polymer to at least a decomposition temperature of the pre-ceramic polymer. The decomposition temperature of the pre-ceramic polymer is less than a sintering temperature of the ceramic powder. The method further includes removing excess ceramic powder that the pre-ceramic polymer was not deposited onto.

First claim

What is claimed is:

1. An apparatus comprising:
a roller adapted to deposit layers of a detonation nanodiamond powder in an inert atmosphere;
a print head adapted to deposit layers of pre-ceramic polymers comprising: poly(hydridocarbyne) dissolved in a solvent in shapes corresponding to cross sections of an object in an inert atmosphere, wherein;
the roller and the print head alternately deposit layers of the detonation nanodiamond powder and the pre-ceramic polymer until the layers of the pre-ceramic polymer form the shape of the object;

a heater operable to heat the deposited detonation nanodiamond powder and poly(hydridocarbyne), in an inert atmosphere, to a temperature sufficient to cause the poly(hydridocarbyne) to form polycrystalline diamond; and
a tool for removing excess detonation nanodiamond powder that the pre-ceramic polymer was not deposited onto.

2. The apparatus of claim 1 , wherein the solvent comprises one or more of acetone, tetra hydrofuran, toluene, or acetonitrile.

3. The apparatus of claim 1 , wherein the deposited detonation nanodiamond powder and poly(hydridocarbyne) is heated to temperature of at least 100 degrees Celsius and less than or equal to 800 degrees Celsius.

4. The apparatus of claim 1 , wherein the roller waits for the solvent to evaporate after a layer of poly(hydridocarbyne) is deposited before depositing a subsequent layer of detonation nanodiamond powder.

5. The apparatus of claim 1 , wherein an average diameter of particles of the detonation nanodiamond powder is less than or equal to 30 nanometers.

6. An apparatus comprising:
a roller adapted to deposit layers of a ceramic powder;
a print head adapted to deposit layers of a pre-ceramic polymer dissolved in a solvent in shapes corresponding to cross sections of an object, wherein;
the roller and the print head alternately deposit layers of the ceramic powder and the pre-ceramic polymer until the layers of the pre-ceramic polymer form the shape of the object;

a heater operable to heat the deposited ceramic powder and pre-ceramic polymer to at least a decomposition temperature of the pre-ceramic polymer, wherein the decomposition temperature of the pre-ceramic polymer is less than a sintering temperature of the ceramic powder; and
a tool for removing excess ceramic powder that the pre-ceramic polymer was not deposited onto.

7. The apparatus of claim 6 , wherein the pre-ceramic polymer is one of poly(hydridocarbyne) or poly(methylsilyne).

8. The apparatus of claim 6 , wherein the solvent comprises one or more of acetone, tetra hydrofuran, toluene, or acetonitrile.

9. The apparatus of claim 6 , wherein the ceramic powder comprises one or more of detonation nanodiamond powder, silicon carbide powder, graphene nano-platlet powder, graphene oxide nano-platelet powder, carbon nanotube powder, fullerene powder, boron nitride nano-platelet powder, or a carbide forming metal powder.

10. The apparatus of claim 6 , wherein the deposited ceramic powder and pre-ceramic polymer is heated to temperature of at least 100 degrees Celsius and less than or equal to 800 degrees Celsius in an inert atmosphere.

11. The apparatus of claim 6 , wherein the roller waits for the solvent to evaporate after a layer of pre-ceramic polymer is deposited before depositing a subsequent layer of ceramic powder.

12. The apparatus of claim 6 , wherein the apparatus further comprises a vacuum operable to draw a vacuum on the deposited ceramic powder and pre-ceramic polymer before heating.

13. The apparatus of claim 6 , wherein an average diameter of particles of the ceramic powder is less than or equal to 30 nanometers.

14. An apparatus comprising:
a roller adapted to deposit layers of a ceramic powder in an inert atmosphere;
a print head adapted to deposit layers of a pre-ceramic polymer dissolved in a solvent in shapes corresponding to cross sections of an object in an inert atmosphere, wherein;
the roller and the print head alternately deposit layers of the ceramic powder and the pre-ceramic polymer until the layers of the pre-ceramic polymer form the shape of the object;

a heater operable to heat the deposited ceramic powder and pre-ceramic polymer to at least a decomposition temperature of the pre-ceramic polymer in an inert atmosphere, wherein the decomposition temperature of the pre-ceramic polymer is less than a sintering temperature of the ceramic powder; and
a tool for removing excess ceramic powder that the pre-ceramic polymer was not deposited onto.

15. The apparatus of claim 14 , wherein the pre-ceramic polymer is one of poly(hydridocarbyne) or poly(methylsilyne).

16. The apparatus of claim 14 , wherein the solvent comprises one or more of acetone, tetra hydrofuran, toluene, or acetonitrile.

17. The apparatus of claim 14 , wherein the ceramic powder comprises one or more of detonation nanodiamond powder, silicon carbide powder, graphene nano-platlet powder, graphene oxide nano-platelet powder, carbon nanotube powder, fullerene powder, boron nitride nano-platelet powder, or a carbide forming metal powder.

18. The apparatus of claim 14 , wherein the deposited ceramic powder and pre-ceramic polymer is heated to temperature of at least 100 degrees Celsius and less than or equal to 800 degrees Celsius.

19. The apparatus of claim 14 , wherein the roller waits for the solvent to evaporate after a layer of pre-ceramic polymer is deposited before depositing a subsequent layer of ceramic powder.

20. The apparatus of claim 14 , wherein an average diameter of particles of the ceramic powder is less than or equal to 30 nanometers.

Assignees

• Lockheed Corp

Inventors

• Findley David G

Classifications

• C04B35/52

  based on carbon, e.g. graphite · CPC title

• B28B1/001 Primary

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• C04B35/622

  Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products · CPC title

• C04B2235/483

  Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title